Method and apparatus of nondestructive testing a sealed product for leaks

ABSTRACT

A method of testing a product for leaks includes applying to the product a reference pressure that is less than 50.6 KPa. The method also includes developing a gas flow through a leak detection sensor in response to applying the reference pressure to the product. Another step of the method includes determining, based upon the gas flow between the product and the pressure system, whether the product leaked an unacceptable amount during the test period.

RELATED APPLICATION

[0001] This application is a divisional application of U.S. patentapplication Ser. No. 09/773,474, filed Feb. 1, 2001, the entiredisclosure of which is hereby incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention relates to product testing, and morespecifically to testing a product for leaks.

BACKGROUND OF THE INVENTION

[0003] Many products are produced in an air-tight manner forenvironmental, health, freshness, operational and/or other reasons. Tomeet the need for air-tight products, test equipment have been developedto test certain types of products for leaks. For example, U.S. Pat. No.5,861,546 ('546 patent) to Sagi et al., the disclosure of which ishereby incorporated by reference, discloses a leak detection apparatusthat is suitable for detecting leaks in a product having an opening towhich a leak sensor and a vacuum system may be coupled in order to forma closed test system.

SUMMARY OF THE INVENTION

[0004] All pressure values provided are absolute pressures (i.e. notgauge pressures) unless otherwise indicated. The present inventionutilizes technology which the Applicant has named “Mass ExtractionTechnology”. A leak detection sensor that embodies Mass ExtractionTechnology generally measures the amount of total mass or mass flow ofair or any other gas extracted from a product while the product isexposed to a constant vacuum. The mass extracted is related to a virtualdefect size or virtual pin hole size of the product under test. Since ata given temperature and pressure, mass and volume of a gas arecorrelated, a leak detection sensor that embodies Mass ExtractionTechnology may alternatively measure the amount of total volume orvolumetric flow of air or any other gas extracted from a product whilethe product is exposed to a vacuum. Leak detection sensors embodying theMass Extraction Technology of the present invention can be manufacturedto be extremely sensitive and measure levels as small as 1*10⁻⁶ std.cc/sec. or 0.15 micrograms/min at 0.133 KPa. Due to this extremesensitivity with any gas, leak detection sensors of the presentinvention can be used to perform tests with inexpensive gases such asair or nitrogen which previously required much more expensive techniquesand gases such as Helium Mass Spectrometry.

[0005] Pursuant to an exemplary embodiment, there is provided a methodof testing a product for leaks. One step of the method includes applyingto the product a reference pressure that is less than 50.6 KPa. Anotherstep of the method includes developing a gas flow through a leakdetection sensor in response to applying the reference pressure to theproduct. The method also includes the step of determining, based uponthe gas flow between the product and the pressure system, whether theproduct leaked an unacceptable amount during the test period.

[0006] Pursuant to another exemplary embodiment, there is provided aleak detection system for testing a product for leaks. The leakdetection system includes a chamber dimensioned to receive the product,a pressure system that maintains a pressure of less than 50.6 KPa duringa test period, and a leak sensor coupled to the chamber via a firstconduit and the pressure system via a second conduit. The leak sensor isoperable to receive the reference pressure via the second conduit andapply the reference pressure to the chamber via the first conduit. Theleak sensor is also operable to develop a gas flow from the chamberthrough the leak sensor to the pressure system as a result of applyingthe reference pressure to the chamber. The leak sensor is furtheroperable to determine, based upon the gas flow between the chamber andthe pressure system, whether the product leaked an unacceptable amountduring the test period.

[0007] Pursuant to yet another exemplary embodiment, there is provided aleak detection system for testing a product having an opening for leaks.The leak detection system includes a pressure system that maintains apressure of less than 50.6 KPa during a test period, and a leak sensorcoupled to the opening of the product via a first conduit and thepressure system via a second conduit. The leak sensor is operable toreceive the reference pressure via the second conduit and apply thereference pressure to the product via the first conduit. The leak sensoris also operable to develop a gas flow from the product through the leaksensor to the pressure system as a result of applying the referencepressure to the product. The leak sensor is further operable todetermine, based upon the gas flow between the product and the pressuresystem, whether the product leaked an unacceptable amount during thetest period.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 is a schematic diagram of a first exemplary leak detectionsystem;

[0009]FIG. 2 is a perspective view of the exemplary test chamber shownin FIG. 1;

[0010]FIG. 3 is a flowchart of an exemplary leak detection methodimplemented by the first leak detection system shown in FIG. 1;

[0011]FIG. 4 is a schematic diagram of a second exemplary leak detectionsystem;

[0012]FIG. 5 is a flowchart of an exemplary leak detection methodimplemented by the second leak detection system shown in FIG. 4;

[0013]FIG. 6 is a schematic diagram of a third exemplary leak detectionsystem;

[0014]FIG. 7 is a flowchart of an exemplary leak detection methodimplemented by the third leak detection system shown in FIG. 6;

[0015]FIG. 8 is a schematic diagram of a fourth exemplary leak detectionsystem;

[0016]FIG. 9 is a flowchart of an exemplary leak detection methodimplemented by the fourth leak detection system shown in FIG. 8;

[0017]FIG. 10 is a section diagram of a first IGLS design for theintelligent gas leak sensor of the leak detection systems shown in FIGS.1, 4, 6, and 8;

[0018]FIG. 11 is an end view of the cylindrical portion of the centershaft of the intelligent gas leak sensors shown in FIGS. 1, 4, 6, and 8;

[0019]FIG. 12 is an detail view of the cylindrical portion and chamferof the center shaft the intelligent gas leak sensors shown in FIG. 1, 4,6, and 8;

[0020]FIG. 13 is an end view of the spacer of the intelligent gas leaksensors shown in FIGS. 1, 4, 6, and 8;

[0021]FIG. 14 is a side view of the spacer shown in FIG. 13; and

[0022]FIG. 15 is a section view of the flow pattern of gas throughintelligent gas leak sensors implementing the first IGLS design of FIG.10.

[0023]FIG. 16 is a section diagram of a second IGLS design for theintelligent gas leak sensor of the leak detection systems shown in FIGS.1, 4, 6, and 8;

[0024]FIG. 17 is a section diagram of the body and manifold of theintelligent leak sensor shown in FIG. 16; and

[0025]FIG. 18 is a top view of the manifold shown in FIG. 17.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0026] While the invention is susceptible to various modifications andalternative forms, exemplary embodiments thereof have been shown by wayof example in the drawings and will herein be described in detail. Itshould be understood, however, that there is no intent to limit theinvention to the particular forms disclosed, but on the contrary, theintention is to cover all modifications, equivalents, and alternativesfalling within the spirit and scope of the invention as defined by theappended claims.

[0027]FIG. 1 shows a schematic of a first exemplary leak detectionsystem 20 that incorporates various features of the present invention.The first exemplary leak detection system 20 includes an intelligent gasleak sensor (IGLS) 9 and a pressure system 14. Furthermore, theexemplary leak detection system 20 may further include a test chamber 12which is used to test products or units under test (UUT). The testchamber 12 is coupled to the IGLS 9 via an inlet conduit 15 comprisingan exhaust valve 10, and the IGLS 9 is coupled to the pressure system 14via an outlet conduit 16 comprising a needle valve 8. Furthermore, thetest chamber 12 is coupled to the pressure system 14 via a by-passconduit 17 comprising a by-pass valve 11 which provide a gas flow paththat by-passes the IGLS 9.

[0028] The pressure system 14 is generally operable to maintain areference pressure less than the surrounding environment in which theleak detection system 20 is operated. To this end, the pressure system14 in an exemplary embodiment includes a vacuum accumulator 7, apressure gauge 6, a vacuum pump 5, a pressure gauge 4, a pressurecontrol valve 3, an air filter 2, and a ball valve 1 that are seriallycoupled to one another between an air supply and the outlet conduit 16.In operation, the vacuum accumulator 7 helps to reduce pressurefluctuations within the pressure system 14 and significantly increasesoverall system performance.

[0029] The IGLS 9 in an exemplary embodiment is operable to controlclamping of the test chamber 12, control the exhaust valve 10, andcontrol the by-pass valve 11. Moreover, the IGLS 9 is generally operableto obtain various measurements of gas flow between the test chamber 12and the pressure system 14. In particular, the IGLS 9 is operable toobtain a measurement of the gas flow through the IGLS 9 at a particularpoint in time while controlling a near constant pressure within the IGLS9 throughout a test period, calculate total mass, total volume, massflow, and/or volumetric flow of the gas flow through the IGLS 9 duringthe test period, and determine whether a UUT such as a sealed packagehas a leak failure based upon the calculated total mass, total volume,mass flow rate, or volumetric flow rate of the gas flow through the IGLS9 during the test period.

[0030] The test chamber 12 of the leak detection system 20 is generallyoperable to receive a UUT such as an air-tight package containingmedical supplies, and subject the UUT to a controlled pressurizedenvironment. To this end, the test chamber 12 as depicted in FIG. 2includes a receptacle 22 dimensioned to receive the UUT to be tested forleaks, and a cover 24 that when placed in position with the receptacle22 is operable to seal the receptacle 22 in an air-tight manner. Inorder to alter the internal pressure of the test chamber 12 and subjectthe UUT to a pressurized environment, the test chamber 12 furtherincludes a outlet port 26 that provides a controllable gas flow pathfrom the interior of the test chamber 12 to the exterior of the testchamber 12. In operation, the outlet port 26 is coupled to the pressuresystem 14 via the inlet conduit 15 in order to extract gas from the testchamber 12 in a controlled manner and to subject the UUT to thereference pressure maintained by the pressure system 14.

[0031] The test chamber 12 further includes a grid 28 that in theexemplary embodiment performs several functions. In particular, the grid28 helps to prevent excessive contamination of the IGLS 9 by filteringcontaminates from the gas flow. Moreover, the grid 28 helps to preventthe sealed package from blocking gas flow through the outlet port 26.Furthermore, the grid 28 along with other product supports (not shown)of the test chamber 12 help reduce mechanical stress exerted upon theUUT. Those skilled in the art should appreciate that when the internalpressure of the test chamber 12 is less than the internal pressure of aflexible UUT such as a sealed medical package, the flexible UUT willexpand due to the lower pressure developed within the test chamber 12.The grid 26 along with other product supports of the test chamber 12helps to reduce the amount a flexible sealed UUT expands within the testchamber 12 in order to prevent the destruction of the sealed UUT. Inparticular, the test chamber 12 of an exemplary embodiment has aclamshell design in which the grid 26 and the other product supportsprovide a near form fit to the UUT in order to minimize the dead volumewithin the test chamber 12 during a test and thereby improve theresponse time of the test.

[0032] Referring now to FIG. 3, there is illustrated a flowchart of anexemplary leak detection method 30 implemented by the leak detectionsystem 20. In particular, the leak detection method 30 begins in step 31with the placement of the UUT into the receptacle 22 of the test chamber12. In an exemplary automated system, a mechanical arm or other deviceplaces the UUT into the test chamber 12. Alternatively, a person couldplace the UUT into the receptacle 22. Then in step 32, the IGLS 9generates a clamp signal that causes the cover 24 of the test chamber 12to clamp into place and seal the test chamber 12. Alternatively, aperson could place the cover 24 into place and seal the test chamber 12.After the test chamber 12 is sealed, the IGLS 9 in step 33 generates oneor more control signals that cause the exhaust valve 10 to operablydecouple the outlet port 26 of the test chamber 12 from the surroundingenvironment and couple the outlet port 26 of the test chamber 12 to thepressure system 14 thus creating a closed test system.

[0033] In the exemplary embodiment, the IGLS 9 in step 34 generates oneor more control signals that cause the by-pass valve 11 to open for apredetermined quick extraction period (e.g. 3 to 5 seconds). As resultof opening the by-pass valve 11, the pressure system 14 via the by-passconduit 17 quickly extracts mass from the test chamber 12 to quicklybring the internal pressure of the test chamber 12 closer to thereference pressure maintained by the pressure system 14. In theexemplary embodiment, the IGLS 9 provides a more restrictive gas flowpath between the test chamber 12 and the pressure system 14 than the gasflow path provided by the by-pass conduit 17. Accordingly, opening theby-pass valve 11 causes the internal pressure of the test chamber 12 tomore quickly approach the reference pressure maintained by the pressuresystem 14 and reduce the overall time required to test the UUT. In anexemplary embodiment, the predetermined quick extraction period isdetermined during a calibration process for the type of test chamber 12to be used and the type of sealed UUT to be tested. From the calibrationprocess, the exemplary embodiment determines a quick extraction periodthat is sufficient for the pressure system 14 to bring the internalpressure of the test chamber 12 near the reference pressure maintainedby the pressure system 14.

[0034] After performing the quick extraction operation in step 34, theIGLS 9 in step 35 generates one or more control signals that cause theby-pass valve 11 to close and then waits for a predeterminedstabilization period (e.g. 0.8 seconds). As a result of closing theby-pass valve 11, gas flow between the test chamber 12 and the pressuresystem 14 is restricted to pass through the IGLS 9. The IGLS 9 in step36 initializes a gas flow parameter (e.g. total mass value, total volumevalue, mass flow rate, volumetric flow rate) indicative of a virtualdefect size of the UUT. In particular, the IGLS 9 in an exemplaryembodiment initializes the gas flow parameter to a value of zero.

[0035] The IGLS 9 in step 37 calculates a gas flow parameter of the gasflow through the IGLS 9 during a predetermined test period (e.g. 5-10seconds). In order to calculate the gas flow parameter, the IGLS 9 in anexemplary embodiment generates at periodic intervals a mass flow ratevalue (dM/dt)_(n) representative of the mass flow rate of gas throughthe IGLS 9 during an interval n and updates the total mass value M aftereach periodic interval n by adding to the current total mass value M,the product of the mass flow rate value (dM/dt)_(n) times the durationof the associated interval n. Alternatively, or in addition to, the IGLS9 generates at periodic intervals a volumetric flow rate value(dQ/dt)_(n) representative of the volumetric flow rate of the gasthrough the IGLS 9 during an interval n and updates a total volume valueV after each periodic interval n by adding to the current total volumevalue V, the product of the volumetric flow rate value (dQ/dt)_(n) timesthe duration of the associated interval n.

[0036] The IGLS 9 then in step 38 determines based upon the obtained gasflow parameter (e.g. total mass, total volume, mass flow rate at aparticular point, volumetric flow rate at a particular point) for thegas flow through the IGLS 9 during the test period whether the UUTleaked an unacceptable amount during the test period. More specifically,the IGLS 9 in an exemplary embodiment compares the total mass value Mfor the gas flow during the test period to a predetermined thresholdlevel and determines that the UUT leaked an unacceptable amount if thetotal mass has a predetermined relationship to the threshold level. Forexample, the pressure system 40 in an exemplary embodiment applies areference pressure that is below atmospheric conditions to the testchamber 80 and the IGLS 9 determines that the UUT leaked an unacceptableamount if the total mass extracted during the test period is greaterthan the predetermined threshold. In an alternative embodiment, the IGLS9 compares the total volume value V for the gas flow during the testperiod to a predetermined threshold level and determines that the UUTleaked an unacceptable amount if the total volume has a predeterminedrelationship to (e.g. greater than) the threshold level. Similarly, theIGLS 9 in yet another exemplary embodiment compares the total mass flowrate for the gas flow obtained at a predetermined point during the testperiod to a predetermined threshold level and determines that the UUTleaked an unacceptable amount if the total mass flow rate has apredetermined relationship to (e.g. greater than) the threshold level.

[0037] The leak detection system 20 when testing a series of unitsshould extract a relatively constant amount of mass or volume from thetest chamber 12 during each test period if the units do not leak.Similarly, the leak detection system 20 when testing a series of unitsshould develop similar mass flow rate and volumetric flow ratesignatures during each test period if the units do not leak. However, ifa UUT does leak, then the leak detection system 20 should extractadditional mass or volume from the test chamber 12 that is attributableto the mass leaked by the UUT. Similarly, if a UUT does leak, then theleak detection system 20 should develop a mass flow rate signature or avolumetric flow signature having a greater value at a predeterminedpoint during the test period. In this manner, the leak detection system20 is operable to detect whether a sealed UUT leaked an unacceptableamount during the test period by comparing the total mass, total volume,mass flow rate, and/or volumetric flow rate to a predetermined thresholdlevel.

[0038] It should be appreciated that the total mass, total volume, massflow rate, and volume flow rate are all indicative of a virtual defectsize of the UUT. The virtual defect size of the UUT is essentially ameasurement of the combined effective area of all defects of the UUT.For example, a UUT having 10 defects each having an effective area of 1micrometer squared has a virtual defect size of 10 micrometers squared(i.e. the total effective area of all defects of the UUT). Accordingly,the total mass, total volume, mass flow rate, and volume flow rate canbe related to a virtual hole size to determine whether the UUT meets avirtual defect size requirement. For example, in the medical industry,packages are often required to have a virtual defect size of 0.2micrometers or less which relates to the smallest known living organism.Due to the total mass, total volume, mass flow rate, and volumetric flowrate being dependent upon the virtual defect size of the UUT, the leakdetection system 20, 200, 300, 400 may be configured to determinewhether the UUT satisfies a virtual defect size requirement based uponthese determined gas flow parameters.

[0039] If the IGLS 9 in step 38 determines that the UUT leaked anunacceptable amount during the test period, then the IGLS 9 in step 39provides an indication that the UUT failed the leak test. Conversely, ifthe IGLS 9 in step 38 determines that the UUT did not leak anunacceptable amount during the test period, then the IGLS 9 in step 40provides an indication that the sealed UUT passed the leak test. Asshould be appreciated by those skilled in the art, the IGLS 9 mayprovide the above status indications in many known manners such asdistinguishing audible tones, visible lights, textual displays, and/orelectronic signals. After indicating the status of the sealed UUT, theIGLS 9 generates in step 41 one or more control signals that cause thetest chamber 12 to deplete and the cover 24 of the test chamber 12 tounclamp from the receptacle 22. Alternatively, a person could manuallycause the test chamber 12 to deplete and manually unclamp the cover 24from the receptacle 22 of the test chamber 12.

[0040] Referring now to FIG. 4, a schematic of a second exemplary leakdetection system 200 that incorporates various features of the presentinvention is shown. The second exemplary leak detection system 200includes an intelligent gas leak sensor (IGLS) 220, a controllablepressure system 240, valve controller 260, and a test chamber 280 whichmay be implemented in a manner similar to the test chamber 12 of FIG. 2.The test chamber 280 is coupled to the IGLS 220 via an inlet conduit 270having an inlet valve 272, and the IGLS 220 is coupled to thecontrollable pressure system 240 via an outlet conduit 274. Furthermore,the test chamber 280 is coupled to the controllable pressure system 240via a by-pass conduit 276 having a by-pass valve 277. The by-passconduit 276 and by-pass valve 277 generally provide a controllable gasflow path between the test chamber 280 and the controllable pressuresystem 240 that by-passes the IGLS 220. Furthermore, the test chamber280 is coupled to the surrounding environment via an exhaust valve 278and a muffler 279 that provide a gas flow path for quickly returning theinternal pressure of the test chamber 280 to atmospheric conditions.

[0041] In an exemplary embodiment, the by-pass valve 277 is implementedwith a larger valve than the inlet valve 272. The larger by-pass valve277 provides a less restrictive gas flow thus increasing the flow ratethrough by-pass conduit 276 and reducing a quick extraction period oftime. On the other hand, less air is required in order to fill thesmaller inlet valve 272 than is required to fill the larger by-passvalve 277. Accordingly, the smaller inlet valve 272 helps reduce theresponse time the leak detection system 200 during extremely low flowtest conditions.

[0042] The controllable pressure system 240 is generally operable toapply a reference pressure to the UUT via the IGLS 220 at a level thatis controllable by the IGLS 220. To this end, the controllable pressuresystem 240 in an exemplary embodiment includes a vacuum pump 242, an airfilter 244, a flow controller 246, and an accumulator 248 that areoperably coupled to the IGLS 220 via outlet conduit 274. The vacuum pump242 generally develops a gas flow through the air filter 244, the flowcontroller 246, and the accumulator 248 by extracting air therefrom. Theflow controller 246 is operably coupled to the IGLS 220 in order toallow the IGLS 220 to control the flow of gas through the leak detectionsystem 200. In particular, the flow controller 246 of the exemplaryembodiment comprises a stepper motor (not shown) coupled to a needlevalve (not shown) such that rotation of the stepper motor effects theflow of gas through the needle valve. Accordingly, fine grain control ofthe gas flow through the leak detection system 200 may be maintained viathe flow controller 246 by adjusting an electronic control signalapplied to the stepper motor.

[0043] The valve controller 260 is coupled to the IGLS 220, the inletvalve 272, the by-pass valve 277, and the exhaust valve 278. The valvecontroller 260 generally controls opening and closing of the inlet valve272, the by-pass valve 277, and the exhaust valve 278 based uponinformation received from the IGLS 220. In an exemplary embodiment, theinlet valve 272, the by-pass valve 277, and the exhaust valve 278 arepneumatically operated. Accordingly, the valve controller 260 of theexemplary embodiment includes a first control valve 262 thatpneumatically couples the an air source 269 to the by-pass valve 277 inorder to pneumatically control the opening and closing of the by-passvalve 277. Furthermore, the valve controller 260 of the exemplaryembodiment includes a second control valve 264 that pneumaticallycouples the air source 269 to the inlet valve 272 and the exhaust valve278 in order to pneumatically control the opening and closing of thevalves 272, 278. Furthermore, the first control valve 262 and the secondcontrol valve 264 of the valve controller 260 are pneumatically coupledto the surrounding atmosphere via muffler 268 in order to release air inan audio-dampened manner.

[0044] The first control valve 262 and the second control valve 264 ofthe valve controller 260 are also electrically coupled to the IGLS 220in order to receive electric control signals from the IGLS 220. However,the leak detection system 200 may alternatively be implemented withhydraulically or electrically controlled valves 272, 277, 278. Further,depending upon the input requirements of the valves 272, 277, 278, theIGLS 220 may be implemented to directly control the opening and closingof the valves 272, 277, 278 instead of controlling the opening andclosing of the valves indirectly via the valve controller 260, thuseliminating the need for the valve controller 260.

[0045] The IGLS 220 is operable to control clamping of the test chamber280, control the internal pressure of the IGLS 220 by adjusting the flowcontroller 246, and control the inlet valve 272, the by-pass valve 277,and the exhaust valve 278. Moreover, the IGLS 220 is generally operableto obtain various measurements of gas flow between the test chamber 280and the pressure system 240. In particular, the IGLS 220 is operable toobtain a measurement of the mass flow rate or volumetric flow rate ofthe gas flow through the IGLS 220 at a particular point in time whilecontrolling a near constant pressure within the IGLS 220 throughout atest period, calculate total mass, total volume, mass flow, and/orvolumetric flow of the gas flow through the IGLS 220 during the testperiod, and determine whether a UUT such as a sealed package has a leakfailure based upon the calculated total mass, total volume, mass flowrate and/or volumetric flow rate of the gas flow through the IGLS 220during the test period.

[0046] A flowchart of an exemplary leak detection method 230 implementedby the leak detection system 200 is illustrated in FIG. 5. Inparticular, the leak detection method 230 begins in step 231 with theplacement of the UUT into the test chamber 280. In an exemplaryautomated system, a mechanical arm or other device places the UUT intothe test chamber 280. Alternatively, a person could place the UUT intothe test chamber 280. Then in step 232, the IGLS 220 generates a clampsignal that causes the test chamber 280 to seal in an air tight manner.Alternatively, a person could manually seal the test chamber 280. Afterthe test chamber 280 is sealed, the IGLS 220 in step 233 generates oneor more control signals that cause the exhaust valve 278 to operablydecouple the test chamber 280 from the surrounding environment andcouple the test chamber 280 to the pressure system 240 thus creating aclosed test system.

[0047] In the exemplary embodiment, the IGLS 220 in step 234 generatesone or more control signals that cause the inlet valve 272 to open andthe by-pass valve 278 to open for a predetermined quick extractionperiod (e.g. 3 to 5 seconds). As result of opening the by-pass valve272, the pressure system 240 via the by-pass conduit 278 quicklyextracts mass from the test chamber 280 to quickly bring the internalpressure of the test chamber 280 closer to the reference pressuremaintained by the pressure system 240. In the exemplary embodiment, theIGLS 220 and the inlet valve 272 provides a more restrictive gas flowpath between the test chamber 280 and the pressure system 240 than thegas flow path provided by the by-pass conduit 276 and the by-pass valve277. Accordingly, opening the by-pass valve 277 causes the internalpressure of the test chamber 280 to more quickly approach the referencepressure maintained by the pressure system 240 and reduces the overalltime required to test the UUT. In an exemplary embodiment, thepredetermined quick extraction period is determined during a calibrationprocess for the type of test chamber 280 to be used and the type of UUT.From the calibration process, the exemplary embodiment determines aquick extraction period that is sufficient for the pressure system 240to bring the internal pressure of the test chamber 280 near thereference pressure maintained by the pressure system 240.

[0048] After performing the quick extraction operation in step 234, theIGLS 220 in step 235 generates one or more control signals that causethe by-pass valve 277 to close and then waits for a predeterminedstabilization period (e.g. 0.8 seconds). As a result of closing theby-pass valve 277, gas flow between the test chamber 280 and thepressure system 240 is restricted to pass through the IGLS 220. The IGLS220 in step 236 initializes a gas flow parameter (e.g. total mass value,total volume value, mass flow rate, volumetric flow rate) that isindicative of a virtual defect size of the UUT. In particular, the IGLS220 in an exemplary embodiment initializes the gas flow parameter to avalue of zero.

[0049] The IGLS 220 in step 237 calculates a gas flow parameter of thegas flow through the IGLS 220 during a predetermined test period (e.g.5-10 seconds) and continually adjusts the flow controller 246 in orderto maintain a programmable pressure within the IGLS 220. In particular,the IGLS 220, in an exemplary embodiment, periodically determines thepressure in the IGLS 220 and generates one or more control signals whichcause the flow controller 246 of the controllable pressure system 240 toadjust the pressure applied to the IGLS 220 by an amount needed tomaintain the desired pressure in the IGLS 220. By adjusting the pressurewithin the IGLS 220, the IGLS 220 may more quickly determine whether agiven UUT leaked an acceptable or an unacceptable amount.

[0050] Further, in order to calculate the gas flow parameter, the IGLS220 in an exemplary embodiment generates at periodic intervals a massflow rate value (dM/dt)_(n) representative of the mass flow rate of gasthrough the IGLS 220 during an interval n and updates the total massvalue M after each periodic interval n by adding to the current totalmass value M, the product of the mass flow rate value (dM/dt)_(n) timesthe duration of the associated interval n. Alternatively, or in additionto, the IGLS 220 generates at periodic intervals a volumetric flow ratevalue (dQ/dt)_(n) representative of the volumetric flow rate of the gasthrough the IGLS 220 during an interval n and updates a total volumevalue V after each periodic interval n by adding to the current totalvolume value V, the product of the volumetric flow rate value(dQ/dt)_(n) times the duration of the associated interval n.

[0051] The IGLS 220 then in step 238 determines based upon the obtainedgas flow parameter (e.g. total mass, total volume, mass flow rate at aparticular point, volumetric flow rate at a particular point) for thegas flow through the IGLS 220 during the test period whether the UUTleaked an unacceptable amount during the test period. More specifically,the IGLS 220 in an exemplary embodiment compares the total mass value Mfor the gas flow during the test period to a predetermined thresholdlevel and determines that the UUT leaked an unacceptable amount if thetotal mass has a predetermined relationship to the threshold level. Forexample, the pressure system 240 in an exemplary embodiment applies areference pressure that is below atmospheric conditions to the testchamber 280 and the IGLS 220 determines that the UUT leaked anunacceptable amount if the total mass extracted during the test periodis greater than the predetermined threshold. In an alternativeembodiment, the IGLS 220 compares the total volume value V for the gasflow during the test period to a predetermined threshold level anddetermines that the UUT leaked an unacceptable amount if the totalvolume has a predetermined relationship to (e.g. greater than) thethreshold level. Similarly, the IGLS 220 in yet another exemplaryembodiment compares the total mass flow rate for the gas flow obtainedat a predetermined point during the test period to a predeterminedthreshold level and determines that the UUT leaked an unacceptableamount if the total mass flow rate has a predetermined relationship to(e.g. greater than) the threshold level.

[0052] The IGLS 220 then in step 238 determines based upon the obtainedtotal mass of gas flow through the IGLS 220 during the test periodwhether the UUT leaked an unacceptable amount during the test period.More specifically, the IGLS 220 compares the total mass value M for thegas flow during the test period to a predetermined threshold level anddetermines that the sealed UUT leaked an unacceptable amount if thetotal mass has a predetermined relationship to the threshold level. Forexample, the pressure system 240 in an exemplary embodiment applies areference pressure below atmospheric conditions to the test chamber 280and the IGLS 220 determines that the UUT leaked an unacceptable amountif the total mass extracted during the test period is greater than thepredetermined threshold.

[0053] If the IGLS 220 in step 238 determines that the UUT leaked anunacceptable amount during the test period, then the IGLS 220 in step239 provides an indication that the UUT failed the leak test.Conversely, if the IGLS 220 in step 238 determines that the UUT did notleak an unacceptable amount during the test period, then the IGLS 220 instep 241 provides an indication that the UUT passed the leak test. TheIGLS 220 may provide the above status indications in many known mannerssuch as distinguishing audible tones, visible lights, textual displays,and/or electronic signals. After indicating the status of the UUT, theIGLS 220 generates one or more control signals that cause the exhaustvalve 278 to open and deplete the test chamber 280 in step 343.Alternatively, a person could manually deplete the test chamber 280.

[0054]FIG. 6 shows a schematic of a third exemplary leak detectionsystem 300 that incorporates various features of the present invention.The third exemplary leak detection system 300 includes an intelligentgas leak sensor (IGLS) 320, a controllable pressure system 340, a valvecontroller 360, a test chamber 380, a UUT pressure system 390. The testchamber 380 is coupled to the IGLS 320 via an inlet conduit 370 havingan inlet valve 372, and the IGLS 320 is coupled to the controllablepressure system 340 via an outlet conduit 374. The test chamber 380 isfurther coupled to the controllable pressure system 340 via a by-passconduit 376 having a by-pass valve 377. Furthermore, the test chamber380 is coupled to its surrounding environment via an exhaust valve 378and a muffler 379 that provide a gas flow path for quickly returning theinternal pressure of the test chamber 380 to atmospheric conditions.

[0055] The test chamber 380 of the leak detection system 300 isgenerally operable to receive a UUT, subject the UUT to a controlledpressurized environment, and permit the UUT pressure system 390 toincrease the internal pressure of the UUT. To this end, the test chamber380 may be implemented in a manner similar to the test chamber 12depicted in FIG. 2 but with a further port through which the UUTpressure system 390 may be coupled to an opening of the UUT. In thismanner, the UUT pressure system 390 may increase the internal pressureof the UUT without directly affecting the internal pressure of the testchamber 380. However, if the UUT has a leak, then the UUT pressuresystem 390 will affect the internal pressure of the test chamber 380indirectly as a result of the UUT leaking mass received from the UUTpressure system 390 into the test chamber 380.

[0056] The controllable pressure system 340 is generally operable tomaintain a reference pressure at a level that is controllable by theIGLS 320. To this end, the controllable pressure system 340 may beimplemented in a manner similar to the controllable pressure system 340of FIG. 10 with a vacuum pump 342, an air filter 344, a flow controller346, and an accumulator 348 coupled to the IGLS 320 via the outletconduit 374.

[0057] The UUT pressure system 390 is generally operable to apply a testpressure to the interior of the UUT. More specifically, certain UUTgenerate an elevated internal pressure during normal operation.Accordingly, these UUT need to be designed to operate at these elevatedinternal pressures and tested to ensure that they can operate safely atthese internal operating pressures. The UUT pressure system 390 helpstest that the UUT can safely operate at these internal operatingpressures by subjecting the UUT to a test pressure which may be a normaloperating pressure for the UUT, a maximum rated operating pressure forthe UUT, or slightly above the maximum rated operating pressure for theUUT.

[0058] To this end, the UUT pressure system 390 includes a pressuresource 391 coupled to the UUT via a UUT conduit 394 having a pressureregulator 392 and a charge valve 397. The charge valve 397 is operableto control flow of air through the UUT conduit 394 to the UUT. Moreover,the pressure regulator 392 is operable to regulate the pressure appliedto the UUT. The UUT pressure system 390 further includes an exhaustvalve 398 and a muffler 399 which are coupled to the UUT conduit 394.The exhaust valve 398 and muffler 399 provide a gas flow path forquickly returning the internal pressure of the UUT to atmosphericconditions.

[0059] The valve controller 360 is coupled to the IGLS 320, the inletvalve 372, the by-pass valve 377, the exhaust valve 378, the chargevalve 397, and the exhaust valve 398. The valve controller 360 generallycontrols opening and closing of the inlet valve 372, the by-pass valve377, the exhaust valve 378, the charge valve 397, and the exhaust valve398 based upon information received from the IGLS 320. In an exemplaryembodiment, the inlet valve 372, the by-pass valve 377, the exhaustvalve 378, the charge valve 397, and the exhaust valve 398 arepneumatically operated. Accordingly, the valve controller 360 of theexemplary embodiment includes a first control valve 362 thatpneumatically couples the an air source 369 to the by-pass valve 377 inorder to pneumatically control the opening and closing of the by-passvalve 377. Furthermore, the valve controller 360 of the exemplaryembodiment includes a second control valve 364 that pneumaticallycouples the air source 369 to the inlet valve 372 and the exhaust valve378 in order to pneumatically control the opening and closing of thevalves 372, 378. The valve controller 360 further includes a thirdcontrol valve 366 that pneumatically couples the air source 369 to thecharge valve 397 and the exhaust valve 398 in order to pneumaticallycontrol the opening and closing of the valves 397, 398. Furthermore, thefirst control valve 362, the second control valve 364, and the thirdcontrol valve 366 of the valve controller 360 are pneumatically coupledto the surrounding atmosphere via a muffler 368 in order to release airin an audio-dampened manner.

[0060] The first control valve 362, the second control valve 364, andthe third control valve 366 of the valve controller 360 are alsoelectrically coupled to the IGLS 320 in order to receive electriccontrol signals from the IGLS 320. However, the leak detection system300 may alternatively be implemented with hydraulically or electricallycontrolled valves 372, 377, 378, 397, 398. Further, depending upon theinput requirements of the valves 372, 377, 378, 397, 398, the IGLS 320may be implemented to directly control the opening and closing of thevalves 372, 377, 378, 397, 398 instead of controlling the opening andclosing of the valves indirectly via the valve controller 360, thuseliminating the need for the valve controller 360.

[0061] The IGLS 320 is operable to control clamping of the test chamber380, control the pressure level of the IGLS 320 by adjusting the flowcontroller 346, and control the inlet valve 372, the by-pass valve 377,the exhaust valve 378, the charge valve 397, and the exhaust valve 398.Moreover, the IGLS 320 is generally operable to obtain variousmeasurements of gas flow between the test chamber 380 and the pressuresystem 340. In particular, the IGLS 320 is operable to obtain ameasurement of the mass flow rate of the gas flow through the IGLS 320at a particular point in time while controlling a near constant pressurewithin the IGLS 320 throughout a test period, calculate total mass,total volume, mass flow, and/or volumetric flow of the gas flow throughthe IGLS 320 during the test period, and determine whether a UUT has aleak failure based upon the calculated total mass, total volume, massflow rate, or volumetric flow rate of the gas flow through the IGLS 320during the test period.

[0062] There is illustrated in FIG. 7 a flowchart of an exemplary leakdetection method 330 implemented by the leak detection 300. Inparticular, the leak detection method 330 begins with placing the UUTinto the test chamber 380 in step 311, and coupling the UUT pressuresystem 390 to an opening of the UUT in step 312.

[0063] Then in step 332, the IGLS 320 generates a clamp signal thatcauses the test chamber 380 to seal. Alternatively, a person couldmanually seal the test chamber 380. After the test chamber 380 issealed, the IGLS 120 in step 333 generates one or more control signalsthat cause the exhaust valve 378 to operably decouple the test chamber380 from the surrounding environment and couple the outlet port of thetest chamber 380 to the pressure system 340 thus creating a closed testsystem.

[0064] In the exemplary embodiment, the IGLS 320 in step 334 generatesone or more control signals that cause the inlet valve 372 to open andthe by-pass valve 377 to open for a predetermined quick extractionperiod (e.g. 3 to 5 seconds). As result of opening the by-pass valve377, the pressure system 340 via the by-pass conduit 376 quicklyextracts mass from the test chamber 380 to quickly bring the internalpressure of the test chamber 380 closer to the reference pressuremaintained by the pressure system 340. In the exemplary embodiment, theIGLS 320 provides a more restrictive gas flow path between the testchamber 380 and the pressure system 340 than the gas flow path providedby the by-pass conduit 376. Accordingly, opening the by-pass valve 377causes the internal pressure of the test chamber 380 to more quicklyapproach the reference pressure maintained by the pressure system 340and reduce the overall time required to test the UUT. In an exemplaryembodiment, the predetermined quick extraction period is determinedduring a calibration process for the type of test chamber 380 to be usedand the type of product to be tested. From the calibration process, theexemplary embodiment determines a quick extraction period that issufficient for the pressure system 340 to bring the internal pressure ofthe test chamber 380 near the reference pressure maintained by thepressure system 340.

[0065] After performing the quick extraction operation in step 334, theIGLS 320 in step 335 generates one or more control signals that causethe by-pass valve 377 to close and then waits for a predeterminedstabilization period (e.g. 0.8 seconds). As a result of closing theby-pass valve 377, gas flow between the test chamber 380 and thepressure system 340 is restricted to pass through the IGLS 320.Furthermore, the IGLS 320 in step 335 increases the internal pressure ofthe UUT to the test pressure. To this end, the IGLS 320 generates one ormore control signals which cause the exhaust valve 398 of the UUTpressure system 390 to close in order decouple the opening of the UUTfrom the surrounding atmosphere and cause the charge valve 397 of theUUT pressure system 390 to open in order to couple the air source 391 tothe UUT. The IGLS 320 further adjusts the pressure regulator 392 inorder to increase the internal pressure of the UUT to the desired testpressure. Alternatively, the pressure regulator 392 may be manuallyadjusted in order to increase the internal pressure of the UUT to thedesired test pressure.

[0066] During step 335 and the following test period, the IGLS 320further monitors the static pressure sensed by the static pressuresensor 90, 590 (FIGS. 10 and 16) in order to determine whether the UUThas had a gross failure as a result of increasing its internal pressure.More specifically, the IGLS 320 in an exemplary embodiment determinesthat the UUT has had a gross failure if the static pressure of the IGLS320 increases by more than a threshold level over a predetermined periodof time. If the IGLS 320 makes such a determination, then the IGLS 320aborts the test, generates one or more control signals that open theexhaust valves 379, 398, and provides an indication that the UUT failedthe leak test.

[0067] The IGLS 320 then in step 336 initializes a gas flow parameter(e.g. total mass value, total volume value, mass flow rate, volumetricflow rate) indicative of a virtual defect size of the UUT. Inparticular, the IGLS 320 in an exemplary embodiment initializes the gasflow parameter to a value of zero.

[0068] The IGLS 320 in step 337 calculates the gas flow parameter of thegas flow through the IGLS 320 during a predetermined test period (e.g.5-10 seconds) and continually adjusts the flow controller 346 in orderto maintain a programmable pressure within the IGLS 320. In particular,the IGLS 320, in an exemplary embodiment, periodically determines thepressure in the IGLS 320 and generates one or more control signals whichcause the flow controller 346 of the controllable pressure system 340 toadjust the pressure applied to the IGLS 320 by an amount needed tomaintain the desired pressure in the IGLS 320. By adjusting the pressurewithin the IGLS 320, the IGLS 320 may more quickly determine whether agiven UUT leaked an acceptable or an unacceptable amount.

[0069] Further, in order to calculate the gas flow parameter, the IGLS320 in an exemplary embodiment generates at periodic intervals a massflow rate value (dM/dt)_(n) representative of the mass flow rate of gasthrough the IGLS 320 during an interval n and updates the total massvalue M after each periodic interval n by adding to the current totalmass value M, the product of the mass flow rate value (dM/dt)_(n) timesthe duration of the associated interval n. Alternatively, or in additionto, the IGLS 320 generates at periodic intervals a volumetric flow ratevalue (dQ/dt)_(n) representative of the volumetric flow rate of the gasthrough the IGLS 320 during an interval n and updates a total volumevalue V after each periodic interval n by adding to the current totalvolume value V, the product of the volumetric flow rate value(dQ/dt)_(n) times the duration of the associated interval n.

[0070] The IGLS 320 then in step 338 determines based upon the obtainedgas flow parameter (e.g. total mass, total volume, mass flow rate at aparticular point, volumetric flow rate at a particular point) for thegas flow through the IGLS 320 during the test period whether the UUTleaked an unacceptable amount during the test period. More specifically,the IGLS 320 in an exemplary embodiment compares the total mass value Mfor the gas flow during the test period to a predetermined thresholdlevel and determines that the UUT leaked an unacceptable amount if thetotal mass has a predetermined relationship to the threshold level. Forexample, the pressure system 340 in an exemplary embodiment applies areference pressure that is below atmospheric conditions to the testchamber 380 and the IGLS 320 determines that the UUT leaked anunacceptable amount if the total mass extracted during the test periodis greater than the predetermined threshold. In an alternativeembodiment, the IGLS 320 compares the total volume value V for the gasflow during the test period to a predetermined threshold level anddetermines that the UUT leaked an unacceptable amount if the totalvolume has a predetermined relationship to (e.g. greater than) thethreshold level. Similarly, the IGLS 320 in yet another exemplaryembodiment compares the total mass flow rate for the gas flow obtainedat a predetermined point during the test period to a predeterminedthreshold level and determines that the UUT leaked an unacceptableamount if the total mass flow rate has a predetermined relationship to(e.g. greater than) the threshold level.

[0071] If the IGLS 320 in step 338 determines that the UUT leaked anunacceptable amount during the test period, then the IGLS 320 in step339 provides an indication that the UUT failed the leak test.Conversely, if the IGLS 320 in step 338 determines that the UUT did notleak an unacceptable amount during the test period, then the IGLS 320 instep 341 provides an indication that the sealed UUT passed the leaktest. The IGLS 320 may provide the above status indications in manyknown manners such as distinguishing audible tones, visible lights,textual displays, and/or electronic signals. After indicating the statusof the UUT, the IGLS 320 generates one or more control signals in step343 that cause the exhaust valve 378 to open and deplete the testchamber 380 and the exhaust valve 399 to open and deplete the internalpressure of the UUT. Alternatively, a person could manually deplete thetest chamber 380.

[0072]FIG. 8 shows a schematic of a fourth exemplary leak detectionsystem 400 that incorporates various features of the present invention.The fourth exemplary leak detection system 400 includes an intelligentgas leak sensor (IGLS) 420, a controllable pressure system 440, and avalve controller 460. The interior of the UUT is pneumatically coupledto the IGLS 420 via an opening of the UUT and an inlet conduit 470comprising an inlet valve 472, and the IGLS 420 is coupled to thecontrollable pressure system 440 via an outlet conduit 474. Furthermore,the inlet conduit 470 is coupled to the surrounding environment via anexhaust valve 478 and muffler 479 that provide a gas flow path forquickly returning the internal pressure of the UUT to atmosphericconditions.

[0073] The controllable pressure system 440 is generally operable tomaintain a reference pressure at a level that is controllable by theIGLS 420. To this end, the controllable pressure system 440 may beimplemented in a manner similar to the controllable pressure system 240of FIG. 4 with a vacuum pump 442, an air filter 444, a flow controller446, and an accumulator 448 that are coupled to the IGLS 420 via theoutlet conduit 474.

[0074] The valve controller 460 is coupled to the IGLS 420, the inletvalve 472, the by-pass valve 477, and the exhaust valve 478. The valvecontroller 460 generally controls opening and closing of the inlet valve472, the by-pass valve 477, and the exhaust valve 478 based uponinformation received from the IGLS 420. In an exemplary embodiment, theinlet valve 472, the by-pass valve 477, and the exhaust valve 478 arepneumatically operated. Accordingly, the valve controller 460 of theexemplary embodiment includes a first control valve 462, a secondcontrol valve 464, and a muffler 469 which operate in a manner similarto the valve controller 260 of FIG. 12.

[0075] The IGLS 420 is operable to control the pressure level of theIGLS 420 by adjusting the flow controller 446, and control the inletvalve 472, the by-pass valve 477, and the exhaust valve 478. Moreover,the IGLS 420 is generally operable to obtain various measurements of gasflow between the UUT and the pressure system 440. In particular, theIGLS 420 is operable to obtain a measurement of the mass flow rate ofthe gas flow through the IGLS 420 at a particular point in time whilecontrolling a near constant pressure within the IGLS 420 throughout atest period, calculate total mass, total volume, mass flow, and/orvolumetric flow of the gas flow through the IGLS 420 during the testperiod, and determine whether the UUT has a leak failure based upon thecalculated total mass, total volume, mass flow rate, or volumetric flowrate of the gas flow through the IGLS 420 during the test period.

[0076] There is illustrated in FIG. 9 a flowchart of an exemplary leakdetection method 430 implemented by the leak detection system 400. Inparticular, the leak detection method 430 begins in step 431 by couplingthe UUT to the IGLS 420. More specifically, the inlet conduit 470 of theleak detection system 400 is coupled to an opening of the UUT in orderto pneumatically couple the interior of the UUT to the IGLS 420.

[0077] In the exemplary embodiment, the IGLS 420 in step 434 generatesone or more control signals that cause the inlet valve 472 to open andthe by-pass valve 477 to open for a predetermined quick extractionperiod (e.g. 3 to 5 seconds). As result of opening the by-pass valve477, the pressure system 440 via the by-pass conduit 476 quicklyextracts mass from the UUT to quickly bring the internal pressure of theUUT closer to the reference pressure maintained by the pressure system440. In the exemplary embodiment, the IGLS 420 provides a morerestrictive gas flow path between the test chamber 480 and the pressuresystem 440 than the gas flow path provided by the by-pass conduit 476.Accordingly, opening the by-pass valve 477 causes the internal pressureof the test chamber 480 to more quickly approach the reference pressuremaintained by the pressure system 440 and reduce the overall timerequired to test the UUT. In an exemplary embodiment, the predeterminedquick extraction period is determined during a calibration process forthe type of unit to be tested. From the calibration process, theexemplary embodiment determines a quick extraction period that issufficient for the pressure system 440 to bring the internal pressure ofthe test chamber 480 near the reference pressure maintained by thepressure system 440.

[0078] After performing the quick extraction operation in step 434, theIGLS 420 in step 435 generates one or more control signals that causethe by-pass valve 477 to close, and then waits for a predeterminedstabilization period (e.g. 0.8 seconds). As a result of closing theby-pass valve 477, gas flow between the UUT and the pressure system 440is restricted to pass through the IGLS 420. The IGLS 420 in step 436initializes a gas flow parameter (e.g. total mass value, total volumevalue, mass flow value). In particular, the IGLS 420 in an exemplaryembodiment initializes the gas flow parameter to a value of zero.

[0079] The IGLS 420 in step 437 calculates a gas flow parameter of thegas flow through the IGLS 420 during a predetermined test period (e.g.5-10 seconds) and continually adjusts the flow controller 446 in orderto maintain a programmable pressure within the IGLS 420. In particular,the IGLS 420, in an exemplary embodiment, periodically determines thepressure in the IGLS 420 and generates one or more control signals whichcause the flow controller 446 of the controllable pressure system 440 toadjust the pressure applied to the IGLS 420 by an amount needed tomaintain the desired pressure in the IGLS 420. By adjusting the pressurewithin the IGLS 420, the IGLS 420 may more quickly determine whether agiven UUT leaked an acceptable or an unacceptable amount.

[0080] Further, in order to calculate the gas flow parameter, the IGLS420 in an exemplary embodiment generates at periodic intervals a massflow rate value (dM/dt)_(n) representative of the mass flow rate of gasthrough the IGLS 420 during an interval n and updates the total massvalue M after each periodic interval n by adding to the current totalmass value M, the product of the mass flow rate value (dM/dt)_(n) timesthe duration of the associated interval n. Alternatively, or in additionto, the IGLS 420 generates at periodic intervals a volumetric flow ratevalue (dQ/dt)_(n) representative of the volumetric flow rate of the gasthrough the IGLS 420 during an interval n and updates a total volumevalue V after each periodic interval n by adding to the current totalvolume value V, the product of the volumetric flow rate value(dQ/dt)_(n) times the duration of the associated interval n.

[0081] The IGLS 420 then in step 438 determines based upon the obtainedgas flow parameter (e.g. total mass, total volume, mass flow rate at aparticular point, volumetric flow rate at a particular point) for thegas flow through the IGLS 420 during the test period whether the UUTleaked an unacceptable amount during the test period. More specifically,the IGLS 420 in an exemplary embodiment compares the total mass value Mfor the gas flow during the test period to a predetermined thresholdlevel and determines that the UUT leaked an unacceptable amount if thetotal mass has a predetermined relationship to the threshold level. Forexample, the pressure system 440 in an exemplary embodiment applies areference pressure that is below atmospheric conditions to the testchamber 480 and the IGLS 420 determines that the UUT leaked anunacceptable amount if the total mass extracted during the test periodis greater than the predetermined threshold. In an alternativeembodiment, the IGLS 420 compares the total volume value V for the gasflow during the test period to a predetermined threshold level anddetermines that the UUT leaked an unacceptable amount if the totalvolume has a predetermined relationship to (e.g. greater than) thethreshold level. Similarly, the IGLS 420 in yet another exemplaryembodiment compares the total mass flow rate for the gas flow obtainedat a predetermined point during the test period to a predeterminedthreshold level and determines that the UUT leaked an unacceptableamount if the total mass flow rate has a predetermined relationship to(e.g. greater than) the threshold level.

[0082] If the IGLS 420 in step 438 determines that the UUT leaked anunacceptable amount during the test period, then the IGLS 420 in step439 provides an indication that the UUT failed the leak test.Conversely, if the IGLS 420 in step 438 determines that the UUT did notleak an unacceptable amount during the test period, then the IGLS 420 instep 441 provides an indication that the sealed UUT passed the leaktest. The IGLS 420 may provide the above status indications in manyknown manners such as distinguishing audible tones, visible lights,textual displays, and/or electronic signals. After indicating the statusof the UUT, the IGLS 420 generates one or more control signals in step443 that cause the exhaust valve 478 to open and deplete the internalpressure of the UUT. Alternatively, a person could manually activate theexhaust valve 478 to deplete the internal pressure of the UUT.

[0083] An exemplary first IGLS design suitable for implementing the IGLS9 of FIG. 1, the IGLS 220 of FIG. 4, the IGLS 320 of FIG. 6, and/or theIGLS 420 of FIG. 8 is depicted in FIG. 10. As depicted, the first IGLSdesign includes a body 46 made of 316 stainless steel or other similarmaterial for improved tolerance characteristics, machining capabilities,temperature stability and increased tolerance to various gases. The body46 has a first end portion 48 and a second end portion 50. The externalprofile of the body 46 is cylindrical and varies in size in correlationto the flow rate of the gas. A conical-shaped center shaft 42 isinserted into a precisely machined conical bore 44 within the body 46.The center shaft 42 comprises a cylindrical portion 52, a chamfer 54,and a conical portion 56.

[0084] The cylindrical portion 52, better illustrated in FIG. 11, alsocontains a first machined bore 58 for receipt of a dowel pin (not shown)which allows the dowel pin to be press fit into the first machined bore58. The body 46 contains a second machined bore (not shown) which allowsthe dowel pin to pass through the second machined bore forming a keywaysuch that the center shaft 42 can be removed and cleaned without theneed for recalibration, i.e. the center shaft 42 can be inserted intoits original position in terms of orientation.

[0085] Preferably the conical portion 56 of the center shaft 42 shallhave a total angle between 1 degree and 10 degrees with an optimum angleof 2 to 6 degrees. The location of the center shaft 42 within the bore44 is positioned in part by the use of a spring washer (not shown) andforms a laminar flow gap 60 between the inner portion of the bore 44 andthe conical portion 56 of the center shaft 42. The laminar flow gap 60is uniform along the length of the conical portion 56 of the centershaft 42 such that a laminar flow of gas through the laminar flow gap 60results. Laminar flow of gas through the laminar flow gap 60 providesmore accurate pressure measurements and flow calculations than wouldresult from more turbulent flow. With the conical shape and the abilityto adjust the center shaft 42 for calibration, the flow can beaccelerated or decelerated to obtain a polynomial relationship for leaktest. The measurement taken is amplified by the use of typicalamplifiers on the market to improve the accuracy of the readings.

[0086] The center shaft 42 has a cylindrical portion 52 preciselylocated in bore 44 to support one end of the conical portion 56 of thecenter shaft 42. Further, as shown in the end view of FIG. 11, theexemplary cylindrical portion 52 comprises a first machined bore 58 forreceipt of a dowel pin and a plurality of holes 62 with the exemplaryembodiment containing six (6) holes 62. Moreover, as shown in FIG. 12,the holes 62 are drilled through the round cylindrical portion 52 of thecenter shaft 42, such that an opening or equalization chamber 98 iscreated due to the chamfer 54 of the center shaft 42 immediately afterthe cylindrical portion 52 of the center shaft 42 that allows the gas toflow in an orderly fashion to the laminar flow gap 60 created by thecenter shaft 42 and the conical bore 44. The gas flow enters the holes62 in the cylindrical portion 52 and after striking a chamfer 54, thegas flow is directed toward the conical portion 56 of the center shaft42. The gas then flows along the conical portion 56 within the laminarflow gap 60 created by the conical bore 44 and the outer surface of theconical portion 56 of the center shaft 42 as illustrated in FIG. 15.

[0087] The outlet end 64 of the center shaft 42 is reduced to allow flowto enter outlet ports 72 drilled into the second end portion 50 of thebody 46. Moreover, the outlet end 64 of the center shaft 42 isconfigured to engage with a receiving portion of a spacer 68. As shownin FIG. 15, a male portion of the outlet end 64 in an exemplaryembodiment engages a female portion of the spacer 68. However, theoutlet end 64 could be implemented with a female portion that engages amale portion of the spacer 68, or the outlet end 64 and the spacer 68may be configured with other engagement members. The 6 outlet ports 72in the exemplary embodiment are aligned with six (6) holes 100 in aspacer 68 to allow the gas to flow through an outlet end cap 74. Thebody 46 has the same number of outlet ports 72 drilled in the second endportion 50 of the body 46 to direct the gas flow from the center shaft42 to the spacer 68. As shown in FIGS. 13 and 14, the spacer holes 100align with the outlet ports 72 drilled in the second end portion 50 ofthe body 46 which allows the gas to pass through to the end cap 74. Thespacer 68 further comprises a pin 101 on its outer periphery forinsertion within a hole in the body 46 to allow for preciserepeatability when the components are removed and then reassembled formaintenance cleaning. Moreover, as shown in the side view of FIG. 14,the spacer 68 further comprises a small cylindrical portion 102 thatprotrudes from a larger cylindrical portion 104. The larger cylindricalportion 104 engages the outlet end 64 of the center shaft 42 to hold thecenter shaft 42 in place.

[0088] A section view of the center shaft 42 is shown in FIG. 15 whichillustrates the flow pattern of the device in the leak test mode. Theflow enters the first end portion 48 of the body 46 or the end in whichthe center shaft 42 is larger. The gas flows through the plurality ofholes 62 in the cylindrical portion 52 of the center shaft 42, which inthis instance is 6 holes and enters an equalization chamber 98 formed bythe external shape of the center shaft 42 and the internal bore of thecenter bore 44. The gas then flows up one side of the equalizationchamber 98 and enters the laminar flow gap 60 between the outer portionof the center shaft 42 and the inner portion of the center bore 44. Thelaminar flow gap 60 is uniform for the length of the conical portion 56of the center shaft 42 until the gas reaches the outlet ports 72 for thedevice. The gas flows through the 6 outlet ports 72 drilled in the body46 and through 6 holes in the spacer 68. From there the gas flowsthrough the outlet end cap (not shown).

[0089] Referring back to FIG. 10, a first and second end cap 70 and 74,respectively, are attached to the first and second end portions 48 and50, respectively, of the body 46 to enclose the conical bore 44 andcenter shaft 42 within the body 46. During exemplary operation, thefirst end cap 70 functions as an inlet cap and the second end cap 74functions as an outlet cap. The inlet and outlet end caps 70 and 74,respectively, are attached to the body 46 using typical fastenersavailable on the market, such as screws rotated into threaded holes inthe body 46. The center of the first and second end caps 70 and 74,respectively, contain a first and second bore 76 and 78 to allow the gasto flow through each of the first and second end caps, 70 and 74,respectively.

[0090] The conical portion 56 of the center shaft 42 allows adjustmentof the maximum flow rate through the IGLS by adjusting the position ofthe center shaft 42 within the conical bore 44 and/or by matching theconical portion 56 of the center shaft 42 with the conical bore 44. Conematching allows for better accuracy than cylindrical shapes due toaccuracy effects caused by imperfections on the cylindrical surface andconsequently, the flow rate can be adjusted to a point just above thevalue desired and more accurate leak detection is attained.

[0091] To this end, the center shaft 42 is adjusted within the boreusing the spacer 68 machined to a precise dimension such that the spacer68 located at the outlet end 64 of the center shaft 42 and the springwasher 80 located at the cylindrical portion 52 of the center shaft 42position the center shaft 42 and hold it in place in a calibratedposition. This design provides a unit where the calibration remainsconstant and can be modified with a spacer 68 of a different dimension.

[0092] Alternatively, the center shaft 42 could be calibrated using anadjusting screw or a calibrated locating cylinder at the second endportion 50 of the body 46 or the narrow end of the conical portion 56 ofthe center shaft 42. The spacer 68 is threaded and the adjusting screwcan be adjusted by rotating the adjusting screw clockwise orcounterclockwise to position the center shaft 42 according tocalibration measurements. The adjusting screw and a spring washer 80located at the cylindrical portion 52 of the center shaft 42 apply theappropriate forces to locate the center shaft 42 and hold it in place toprovide for a uniform but adjustable gap 60 between the conical portion56 of the center shaft 42 and the surface of the conical bore 44 withinthe body 46.

[0093] A first receiving port 82 and a second receiving port 84 aredrilled in the body 46 to monitor the pressure differences in thelaminar flow around the conical center shaft 42. The first receiving 82port is drilled into the top side of the body 46 and extends from thetop side of the body 46 to the conical bore 44 within the body 46. Thefirst receiving port 82 can be located anywhere along the conical bore44 where L/h>50. In this equation, the length from the edge of theconical portion 56 of the center shaft 42 to the location of the firstreceiving port 82 is “L” and the height between the outer wall of theconical portion 56 of the center shaft 42 and the inner wall of themachined bore 58 is “h” or the height of the laminar flow gas.

[0094] The second receiving port 84 is also drilled in the top side ofthe body 46 and is located downstream of the first receiving port 82 ortoward the smaller end of the conical center shaft 42. The secondreceiving port 84 also extends from the top side of the body 46 to theconical bore 44. The second receiving port 84 can be located at a secondposition anywhere between the first receiving port 82 and the outlet end64 of the center shaft 42 but it is preferable for the first and secondreceiving ports, 82 and 84, respectively, to be separated by a distancesufficient to maintain a constant differential pressure per inch of flowlength which is usually 2 to 3 inches.

[0095] The positions of the first receiving port 82 and the secondreceiving port 84 are designed to be located sufficiently within thelaminar flow gap 60 such that the laminar flow of the gas is fullydeveloped and little or no turbulence in the gas flow exists. Gas entersthe first receiving port 82 and flows to a first pressure chamber orfirst diaphragm 86 with a movable outer wall. Gas also enters the secondreceiving port 84 and flows through the columnar housing 92 to a secondpressure chamber or second diaphragm 88 also with a movable outer wall.The force that the first pressure chamber 86 exerts against the secondpressure chamber 88 measures the relative displacement of the first andsecond diaphragms, 86 and 88 respectively, and a value for thedifferential pressure can be determined. The first and seconddiaphragms, 86 and 88, respectively, are located off center from thebody 46 and center shaft 42 to minimize volumetric changes and increaseresponse time.

[0096] The first receiving port 82, the second receiving port 84, thefirst diaphragm 86 and the second diaphragm 88 of the exemplaryembodiment define a first pressure sensor or differential pressuresensor that generates a differential pressure signal indicative of thesensed differential pressure. This type of differential pressuremeasurement is termed capacitance technology and is commonly known inthe industry. Moreover, the first receiving port 82, the secondreceiving port 84, the first diaphragm 86 and the second diaphragm 88 ofthe exemplary embodiment form a differential pressure sensor that isoperable to generate the differential pressure signal such that thedifferential pressure signal is linear with respect to the differentialpressure sensed between the first receiving port 82 and the secondreceiving port 84. More specifically, the differential pressure sensorof the exemplary embodiment is operable to sense differential pressuresfrom 0 KPa to 0.0249 KPa, 0.0747 KPa, 0.125 KPa, 0.249 KPa, 1.25 KPa,2.49 KPa, or 6.9 KPa full scale and to generate a linear DC differentialpressure signal between 0 volts and 5 volts full scale in responsethereto.

[0097] The second pressure sensor or static pressure sensor 90 of theexemplary first design is located on the top of the columnar housing 92to measure static pressure within the laminar flow gap 60. In theexemplary embodiment, the static pressure sensor 90 is exposed to thesame gas flow as that of the second diaphragm 88. In an exemplaryembodiment, the static pressure sensor 90 is operable to generate thestatic pressure signal such that the static pressure signal is linearwith respect to the static pressure sensed at the second port 84. Morespecifically, the static pressure sensor 90 of the exemplary embodimentis operable to sense static pressures from 0 KPa to 103.425 KPa, 206.85KPa, 689.5 KPa , or 13,790 KPa full scale and to generate a linear DCstatic pressure signal between 0 volts and 5 volts full scale inresponse thereto.

[0098] A temperature sensor 94 of the exemplary first design is locatedon the side of the columnar housing 92 to measure the temperature withinthe columnar housing 92. The temperature sensor 94 is attached to aportion of the columnar housing 92 which has been machined to a point inwhich the air temperature within the columnar housing 92 is the same asthat of the thin, machined columnar housing 92 wall. The temperaturesensor 94 of the exemplary first design comprises a typical RTD typesensor which are commonly used in the industry. The columnar housing 92has tolerance expansion capabilities by positioning an o-ring at eachend of the columnar housing 92. The o-rings seal the columnar housing 92for accurate measurement but also allow the columnar housing 92 toexpand or contract to allow for temperature differences and dimensionaltolerances. In an exemplary embodiment, the temperature sensor 94 isoperable to sense temperatures between 273 K and 353 K and respectivelygenerate a linear DC temperature signal between 0 volts and 5 volts inresponse thereto.

[0099] A microcontroller 96 is connected to the sensors to record allthe measurements, provide mathematical correlation polynomial equations,perform temperature and pressure compensation, display readings on anLCD display including pressure, flow, total mass, and other messages,control the valve sequence for leak test purposes using digital I/Osignals, communicate to a personal computer for setup and dataacquisition, provide pressure/flow control and send analog signals toremote devices, such as personal computers. The microcontroller 96 cantake such measurements and perform such calculations for gas flowing ineither direction within the body. Further, the microcontroller 96 canmeasure acceleration and deceleration for sensitivity and repeatabilityof the calculations. In an exemplary embodiment, the microcontroller 96includes one or more A/D converters which receive the differentialpressure signal, the static pressure signal, and temperature signal andconvert them to a digital sample or count. The microcontroller 96 mayalternatively be implemented without an A/D converter if thedifferential pressure sensor, the static pressure sensor 90 and thetemperature sensor 94 are implemented to output digital signals insteadof analog signals.

[0100] The microcontroller 96, the differential pressure sensor and thestatic pressure sensor 90 of the exemplary are located within a housingor enclosure to protect the components from damage and to make theentire piece of equipment more attractive. On the outside of theenclosure an LCD display is mounted to display various messages toinform the user of measurement results and other messages. Also locatedon the outside of the enclosure is a start/stop button to start or stopa particular test.

[0101] An exemplary second IGLS design which is also suitable forimplementing the IGLS 9 of FIG. 1, the IGLS 220 of FIG. 4, the IGLS 320of FIG. 6, and/or the IGLS 420 of FIG. 8 is depicted in FIGS. 16 and 17.In particular, the second IGLS design is generally better suited forlower mass and volumetric flow rates than the first IGLS design. Asdepicted, the second IGLS design includes a body 546 made of 316stainless steel or other similar material for improved tolerancecharacteristics, machining capabilities, temperature stability andincreased tolerance to various gases. The body 546 has a first endportion 548 and a second end portion 550. The external profile of thebody 546 is cylindrical and varies in size in correlation to the flowrate of the gas. A conical-shaped center shaft 42 is inserted into aprecisely machined conical bore 544 within the body 546. The centershaft 42 comprises a cylindrical portion 52, a chamfer 54, and a conicalportion 56.

[0102] The cylindrical 52, also contains a first machined bore 58 forreceipt of a dowel pin (not shown) which allows the dowel pin to bepress fit into the first machined bore 58. The body 546 contains asecond machined bore (not shown) which allows the dowel pin to passthrough the second machined bore forming a keyway such that the centershaft 42 can be removed and cleaned without the need for recalibration,i.e. the center shaft 42 can be inserted into its original position interms of orientation.

[0103] Preferably the conical portion 56 of the center shaft 42 shallhave a total angle between 1 degree and 10 degrees with an optimum angleof 2 to 6 degrees. The location of the center shaft 42 within the bore544 is positioned in part by the use of a spring washer (not shown) andforms a flow gap 560 between the inner portion of the bore 544 and theconical portion 56 of the center shaft 42. With the conical shape andthe ability to adjust the center shaft 42 for calibration, the flow canbe accelerated or decelerated to obtain a polynomial relationship forleak test. The measurement taken is amplified by the use of typicalamplifiers on the market to improve the accuracy of the readings.

[0104] The body 546 has the same number of inlet ports 572 drilled inthe first end portion 550 of the body 546 to direct the gas flow fromthe spacer 68 to the center shaft 42. The spacer holes 100 align withthe inlet ports 572 drilled in the first end portion 550 of the body 546which allows the gas to pass through to the end cap 574.

[0105] A first and second end cap 570 and 574, respectively, areattached to the first and second end portions 548 and 550, respectively,of the body 546 to enclose the conical bore 544 and center shaft 42within the body 546. During exemplary operation, the first end cap 570functions as an outlet cap and the second end cap 574 functions as aninlet cap . The outlet and inlet end caps 570 and 574, respectively, areattached to the body 546 using typical fasteners available on themarket, such as screws rotated into threaded holes in the body 546. Thecenter of the first and second end caps 570 and 574, respectively,contain a first and second bore 576 and 578 to allow the gas to flowthrough each of the first and second end caps, 570 and 574,respectively.

[0106] The center shaft 42 is adjusted within the bore 544 using thespacer 68 machined to a precise dimension such that the spacer 68located at the inlet end 564 of the center shaft 42 and the springwasher 580 located at the cylindrical portion 52 of the center shaft 42position the center shaft 42 and hold it in place in a calibratedposition. This design provides a unit where the calibration remainsconstant and can be modified with a spacer 68 of a different dimension.

[0107] Alternatively, the center shaft 42 could be calibrated using anadjusting screw or a calibrated locating cylinder at the second endportion 550 of the body 546 or the narrow end of the conical portion 56of the center shaft 42. The spacer 68 is threaded and the adjustingscrew can be adjusted by rotating the adjusting screw clockwise orcounterclockwise to position the center shaft 42 according tocalibration measurements. The adjusting screw and a spring washer 580located at the cylindrical portion 52 of the center shaft 42 apply theappropriate forces to locate the center shaft 42 and hold it in place toprovide for a uniform but adjustable gap 560 between the conical portion56 of the center shaft 42 and the surface of the conical bore 544 withinthe body 546.

[0108] A first receiving port 582 and a second receiving port 584 aredrilled in the body 546 to monitor the pressure differences in flowaround the conical center shaft 42. The first receiving 582 port isdrilled into the top side of the body 546 and extends from the top sideof the body 546 to the conical bore 544 within the body 546. Asillustrated, the first receiving port 582 is basically located outsideor at the end of the gap 560 created by the conical portion 56 of thecenter shaft 42 and the conical bore 544. More specifically, the firstreceiving port 582 is positioned between the cylindrical portion 52 ofthe center shaft 42 and the first end cap 570.

[0109] The second receiving port 584 is also drilled in the top side ofthe body 546 and is located upstream of the first receiving port 582 ortoward the smaller end of the conical center shaft 42. The secondreceiving port 584 also extends from the top side of the body 546 to theconical bore 544. As illustrated, the second receiving port 584 like thefirst receiving port 582 is basically located outside or at the end ofthe gap 560 created by the conical portion 56 of the center shaft 42 andthe conical bore 544. More specifically, the second receiving port 584is positioned between the inlet end 564 of the center shaft 42 and thesecond end cap 574.

[0110] The second IGLS design further includes a first pressure sensoror differential pressure sensor 586, a second pressure sensor or staticpressure sensor 590, a temperature sensor 594, a manifold 610, and ahousing base plate 620. In general, the manifold 610 is operable toroute gas flow from the first receiving port 582 and the secondreceiving port 584 to the differential pressure sensor 586, the staticpressure sensor 590, and the temperature sensor 594. To this end, themanifold 610 includes a first port 612 and a second port 614 thatrespectively engage the first receiving port 582 and the secondreceiving port 584 via the housing base plate 620. More specifically,the housing base plate 620 is mounted to the body 546 such that a firstport 622 and a second port 624 of the housing base plate 620 engage thefirst receiving port 582 and the second receiving port 584, and themanifold 610 is mounted to the housing base plate 620 such that thefirst port 612 and the second port 614 of the manifold respectivelyengage the first port 622 and the second port 624 of the housing baseplate 620. In an exemplary embodiment, the manifold 610 and the housingbase plate 620 are constructed of 316 standard steel, the housing baseplate 620 is welded to the body 546 such that ports 622, 624 engage thereceiving ports 582, 584. Further, the manifold 610 is attached to thehousing base plate 620 via screws inserted through holes 611 of themanifold 610 and into thread holes 621 of the housing base plate 620.

[0111] The manifold 610 further defines a first flow path 615 thatpneumatically couples the first port 612 to a first port 587 of thedifferential pressure sensor 586 and a second flow path 617 thatpneumatically couples the second port 614 to a second port 589 of thedifferential pressure sensor 588. Moreover, the second flow path 617pneumatically couples the second port 614 to a static pressure sensorport 591 and routes gas flow by a temperature sensor recess 619 of themanifold 610. In this manner, the first flow path 615 and the secondflow path 617 of the manifold 610 during operation respectively exposethe first port 587 and second port 588 of the differential pressuresensor 586 to substantially the same pressure found at the firstreceiving port 582 and the second receiving port 584. Moreover, thesecond flow path 617 further exposes the static pressure sensor port 591with substantially the same pressure found at the second receiving port584 and exposes the temperature sensor recess 619 with substantially thesame temperature found at the second receiving port 584.

[0112] The differential pressure sensor 586 generally generates adifferential pressure signal indicative of the sensed differentialpressure between a first port 587 and a second port 588. In theexemplary embodiment, the first port 587 and the second port 588 arepneumatically coupled to the first receiving port 582 and the secondreceiving port 584 via the manifold 610. Accordingly, the differentialpressure sensor 586 of the exemplary embodiment is operable to generatethe differential pressure signal such that the differential pressuresignal is linear with respect to the differential pressure sensedbetween the first receiving port 582 and the second receiving port 584.More specifically, the differential pressure sensor of the exemplaryembodiment is operable to sense differential pressures from 0 KPa to0.0249 KPa, 0.0747 KPa, 0.125 KPa, 0.249 KPa, 1.25 KPa, 2.49 KPa, or6.72 KPa full scale and to generate a linear DC differential pressuresignal between 0 volts and 5 volts full scale in response thereto.

[0113] The static pressure sensor 590 of the exemplary second design iscoupled to the static pressure sensor port 591 via a columnar housing592 to measure static pressure within the flow gap 560. In the exemplaryembodiment, the static pressure sensor 590 is exposed to the same gasflow as that of the second receiving port 584. In an exemplaryembodiment, the static pressure sensor 590 is operable to generate thestatic pressure signal such that the static pressure signal is linearwith respect to the static pressure sensed at the second port 584. Morespecifically, the static pressure sensor 590 of the exemplary embodimentis operable to sense static pressures from 0 KPa to 1.379 KPa, 103.425KPa, 206.85 KPa, or 689.5 KPa full scale and to generate a linear DCstatic pressure signal between 0 volts and 5 volts full scale inresponse thereto.

[0114] As a result of the first receiving port 582 and the secondreceiving port 584 being located outside or at the end of the gap 560,the differential pressure sensor 586 and the static pressure sensor 590respond more quickly to changes in pressures due to the flow path to thesensors 586, 590 being shorter and not restricted by the flow gap 560.Under low flow conditions, responsiveness becomes more of an issuebecause there is simply less gas flow to influence the pressure sensors586, 590. Moreover, turbulent gas flow is directly related to thevelocity of the gas flow. Accordingly, under low flow conditions,establishing a non-turbulent flow within the flow gap 560 is less of anissue than for the first IGLS design because of the gas flow isrelatively non-turbulent due to the low velocity of the gas flow.

[0115] A temperature sensor 594 of the exemplary second design ismounted in the temperature sensor recess 619 of the manifold 610. Morespecifically, the temperature sensor 594 of the exemplary embodiment ismounted in the temperature sensor recess 619 via a thermal compound orglue. However, the temperature sensor 594 may be mounted to the manifold610 via other manners. Further, the temperature sensor 594 couldessentially be located at any location from which the temperature sensor594 may accurately sense the temperature of the gas flow through thebore 544. The temperature sensor 594 of the exemplary second designcomprises a typical RTD type sensor commonly used in the industry. In anexemplary embodiment, the temperature sensor 94 is operable to sensetemperatures between 273 K and 353 K and respectively generate a linearDC temperature signal between 0 volts and 5 volts in response thereto.

[0116] A microcontroller 596 is connected to the sensors to record allthe measurements, provide mathematical correlation polynomial equations,perform temperature and pressure compensation, display readings on anLCD display including pressure, flow, total mass, and other messages,control the valve sequence for leak test purposes using digital I/Osignals, communicate to a personal computer for setup and dataacquisition, provide pressure/flow control and send analog signals toremote devices, such as personal computers. The microcontroller 596 cantake such measurements and perform such calculations for gas flowing ineither direction within the body. Further, the microcontroller 596 canmeasure acceleration and deceleration for sensitivity and repeatabilityof the calculations. In an exemplary embodiment, the microcontroller 596includes one or more A/D converters which receive the differentialpressure signal, the static pressure signal, and temperature signal andconvert them to a digital sample or count. The microcontroller 596 mayalternatively be implemented without an A/D converter if thedifferential pressure sensor 586, the static pressure sensor 590 and thetemperature sensor 594 are implemented to output digital signals insteadof analog signals. The microcontroller 596 includes one or more D/Aconverters for controlling flow controllers 246, 346, 446 and/orpressure regulator 392.

[0117] The microcontroller 596, the differential pressure sensor and thestatic pressure sensor 90 of the exemplary are located within a housingor enclosure that includes the housing base plate 620 to protect thecomponents from damage and to make the entire piece of equipment moreattractive. On the outside of the enclosure an LCD display is mounted todisplay various messages to inform the user of measurement results andother messages. Also located on the outside of the enclosure is astart/stop button to start or stop a particular test.

[0118] Having set forth the structure of exemplary systems, theequations and computations used to calculate flow and leak detectionwill now be reviewed. As previously indicated, the above leak detectionsystems 20, 200, 300, 400 may be implemented with either the first IGLSdesign of FIG. 10 or the second IGLS design of FIG. 16. As explainedbelow, the leak detection systems 20, 200, 300, 400 may also operate ineither a viscous flow mode or a molecular flow mode. Under a commonclassification scheme, gas flow is classified as being in the continuumflow regime, the slip flow regime, the transition flow regime, or thefree molecule flow regime. Traditionally, the continuum flow regime hasbeen associated with a Knudsen number Kn less than 0.01, the slip flowregime has been associated with a Knudsen number Kn between 0.01 and0.1, the transition flow regime has been associated with a Knudsennumber Kn between 0.1 and 3.0, and the free molecule flow regime hasbeen associated with a Knudsen number Kn greater than 3.0. Classically,the Knudsen number Kn has been defined as shown in equation (1):

Kn=λ/L  (1)

[0119] where λ is the mean free path and L is the significantcharacteristic linear dimension.

[0120] As is known to those skilled in the art, the mean free path λ ismostly dependent upon characteristics of the gas such as temperature,pressure, density, etc whereas the significant characteristic dimensionL is mostly dependent upon the geometry apparatus that the gas isflowing through. Accordingly, a person can easily adjust the operatingconditions and the dimensions of the flow gap 60, 560 in order toachieve the desired Knudsen number Kn and therefore the desiredoperating regime for a given test.

[0121] While different mathematical models may be used to model gas flowin each of the continuum flow regime, the slip flow regime, thetransition flow regime, and the free molecule flow regime, highlyaccurate results have been obtained with the exemplary leak detectionsystems 20, 200, 300, 400 using only two mathematical models tocalculate the total mass extracted during the test period. As usedherein, the first mathematical model is referred to as the viscous flowmodel and the second mathematical model is referred to as the molecularflow model. In an exemplary embodiment, a Knudsen Kn number of 0.6 isused as the cutoff point between the viscous flow model and themolecular flow model. In other words, if the leak detection system 20,200, 300, 400 is configured to develop a gas flow within the flow gap60, 560 having a Knudsen number Kn less than 0.6, then the leakdetection system 20, 200, 300, 400 is further configured to calculatethe gas flow parameter during the test period according to the viscousflow model. Further, if the leak detection system 20, 200, 300, 400 isconfigured to develop a gas flow within the flow gap 60, 560 withKnudsen number Kn greater than 0.6, then the leak detection system isfurther configured to calculate the gas flow parameter during the testperiod according to the molecular flow model.

[0122] Whether using the viscous flow model or the molecular flow model,the flow calculation algorithms of the exemplary embodiment aresegmented into viscosity calculations, density calculations, volumetricflow calculations, mass flow calculations, temperature compensation, andtotal mass calculations. The equations for viscosity calculation anddensity calculation are common. The equations for volumetric flowcalculation, the x value (see below) and mass flow are modifications ofequations contained in a published paper. The Proceeding of the SecondInternational Symposium On Flow on Mar. 23-26, 1981 in St. Louis, Mo.sponsored by Instrument Society of America ISA) and authored by David ATodd. The combination of the use of these equations enables the softwareto use a universal calibration curve that is embedded in themicroprocessor 96, 596. Consequently, the Gas Constant (R),compressibility factor z, and the viscosity data is downloaded from thesoftware program for a particular gas and pressure and the need torecalibrate the sensor is eliminated.

[0123] The equations for temperature compensation were developed toallow for thermal expansion. In an exemplary embodiment, the flowcomponents which come into contact with the gas flow are made of thesame material so that each of the components demonstrates equaltemperature effects.

[0124] Focusing now on the viscous flow model, the temperature dependentviscosity calculation is represented by the following equation (2):

μ=μ₀(1+C(T−T ₀))  (2)

[0125] where μ₀ represents viscosity at temperature T₀; T₀ representsthe calibration temperature; C represents a constant slope for oneparticular gas type; and T represents the temperature of the gas (i.e.the temperature sensed by temperature sensors 94, 594).

[0126] The density calculation is represented by the followingcalculation: $\begin{matrix}{D = \frac{P_{S}}{z*R*T}} & (3)\end{matrix}$

[0127] where D represents the density of the gas; R represents theuniversal gas constant, T represents the absolute temperature of the gasmeasured by the temperature sensor 94, 594 (K); P_(S) represents theabsolute pressure measured by the static pressure sensor 90, 590 (KPa);and z represents a compressibility factor for the gas.

[0128] The x value used in the flow calculations is calculated by thefollowing calculation: $\begin{matrix}{x = \frac{D*{P}}{\mu^{2}}} & (4)\end{matrix}$

[0129] where dP represents the measured differential pressure in A/Dcounts.

[0130] The volumetric flow calculation is based on the polynomialcoefficient and the differential pressure measurement as follows:

Q=(C ₀ +C ₁ x+C ₂ x ² +C ₃ x ³)*μ/D  (5)

[0131] The mass flow calculation is based on the following formula:

dM/dt=(C ₀ +C ₁ x+C ₂ x ² +C ₃ x ³)*μ  (6)

[0132] Coefficients C₀, C₁, C₂ and C₃ generally differ from temperatureto temperature due to the thermal expansion of the center shaft 42.Based on the calibration in the desired temperature range, K wasdeveloped to reflect the changes. K is dependent on the thermalcoefficient a of the material used. Thus, the equations for temperaturecompensation are as follows:

Q=K·(C ₀ +C ₁ x+C ₂ x ² +C ₃ x ³)*μ/D  (7)

dM/dt=K·(C ₀ +C ₁ x+C ₂ x ² +C ₃ x ³)*μ  (8)

K=1+α₁·(T−T ₀)+α₂·(T−T ₀)²  (9)

[0133] From the temperature compensated values for mass flow rate dM/dt,the total mass M of gas flow over a test period T_(p) may be obtainedfrom the following equation: $\begin{matrix}{M = {\int_{0}^{T_{p}}{\left( {{M}/\quad {t}} \right){t}}}} & (10)\end{matrix}$

[0134] which in essence integrates the mass flow rate dM/dt over thetest period T_(p). Those skilled in the art should appreciate that theabove integration may be approximated in a discrete system bymultiplying the mass flow rate (dM/dt)_(n) obtained for each discreteinterval n over the test period T_(p) by the duration t_(n) of eachdiscrete interval n and summing the products as represented by thefollowing equation: $\begin{matrix}{{M = {\sum\limits_{n = 0}^{T_{p}}{\left( {{M}/{t}} \right)_{n}*t_{n}}}}\quad} & (11)\end{matrix}$

[0135] For low leak flow situations, it has been found that coefficientsC₀, C₂, and C₃ of above-equations (9) and (10) are zero or small enoughto equate to zero without effecting the accuracy of the flowmeasurements of the leak detection systems 20, 200, 300, 400.Accordingly, for low leak situations, the volumetric flow of the gasthrough the IGLS is not dependent upon the density of the gas asillustrated by the following equation:

Q=K′*dP·/μ  (12)

[0136] where K′ is a composite coefficient of C₁ times K The mass flowmay then be calculated from the volumetric flow based upon equation(13).

dM/dt=Q*D  (13)

[0137] where Q is the volumetric flow rate calculated based uponequation (12) and D is the density of the gas calculated based uponequation (3).

[0138] The following equation (14) which is equation (13) rewritten forcalculating volumetric flow rate Q better illustrates an amplificationeffect the density D has on the volumetric flow rate Q for a given massflow rate dM/dt:

Q=(dM/dt)/D  (14)

[0139] Accordingly, increasing the volumetric flow rate Q through theIGLS 9, 220, 320, 420 will therefore result in an increased pressuredifferential dP across the IGLS 9, 220, 320, 420 that is applied to thedifferential pressure sensor of the leak detection systems 20, 200, 300,400. From the above equations, it is clear that lowering the staticpressure applied (i.e. the reference pressure) by the pressure systems14, 240, 340, 440 to the UUT with other things remaining equal resultsin an increased volumetric flow rate Q through the IGLS 9, 220, 320,420. In fact, lowering the reference pressure will increase the pressuredifferential dP and the volumetric flow rate Q until the velocity of thegas reaches the speed of sound at which point the flow becomes “choked”flow. Once the velocity of the gas reaches the speed of sound, furtherlowering the reference pressure increases the pressure differential dPbut not the volumetric flow rate Q; however, the increased pressuredifferential dP does result in an increase static pressure sensed by thestatic pressure sensor 90, 590 resulting in higher mass flow M for thesame volumetric flow rate Q.

[0140] Applying a low pressure to the IGLS 9, 220, 320, 420 via thepressure systems 14, 240, 340, 440, accordingly, enables the IGLS 9,220, 320, 420 to accurately measure small mass leak flow (e.g. 5micrograms/min) based upon the above viscous flow model. For example, amass flow rate of approximately 1162 micrograms/min of air at 50.6 KPawill result in a volumetric flow rate of approximately 2 cc/min. Thesame mass leak flow at 101.3 KPa (approximate barometric conditions)will result in a volumetric flow rate of approximately 1 cc/min.Utilizing a strong vacuum of 5 KPa, an exemplary IGLS has beenconstructed which can accurately measure mass flow rates as low as 5micrograms/min of air in the viscous mode of operation. As used herein,a strong vacuum indicates a reference pressure below 50.6 KPa and moreparticularly to a reference pressure between 25.3 KPa and 1.33 KPa.

[0141] Focusing now on the molecular flow model, the Applicant has foundthat the mass flow rate dM/dt through the IGLS 9, 220, 320, 420 islinear with respect to the differential pressure dP sensed by thedifferential pressure sensor regardless of inlet pressure. Accordingly,the IGLS 9, 220, 320, 420 may calculate the mass flow rate based simplyupon the differential pressure dP and calibrations constants as show inthe following equation (15):

dM/dt=C ₄+(C ₅ *dP)  (15)

[0142] where C₄ and C₅ are calibration constants. Since the differentialpressure sensor in an exemplary embodiment generates a differentialpressure signal that is linear with respect to the differential pressureapplied to the differential pressure signal, the IGLS 9, 220, 320, 420simply uses the A/D count or sample for the dP of equation (15).Alternatively, the IGLS 9, 220, 320, 420 may determine the actualdifferential pressure dP and use the determined differential pressure inequation (15).

[0143] In order to enter the molecular flow mode of operation, thepressure systems 14, 240, 340, 440 typically applies an extremely lowpressure to the IGLS 9, 220, 320, 420 in order to develop a gas flowthrough the flow gap 60, 560 having a Knudsen number greater than 0.6.Applying an extremely low pressure to the IGLS 9, 220, 320, 420 via thepressure systems 14, 240, 340, 440, accordingly, enables the IGLS 9,220, 320, 420 to accurately measure small mass leak flow rates. Inparticular, leak detection systems 20, 200, 300, 400 have beenconstructed which can accurately measure mass flow rates below 50micrograms/min, below 10 micrograms/min, below 5 micrograms/min, below 1microgram/min, and below 0.02 micrograms/min. As used herein, anextremely strong vacuum indicates a reference pressure below 1.33 KPa,more particularly to a reference pressure below 0.665 KPa, andparticularly to a reference pressure below 0.133 KPa.

[0144] In the exemplary embodiments, the IGLS 20, 200, 300, 400 usescomputer software embedded in the microcontroller 596 to allow the userto easily adjust the function parameters and incorporate themathematical equations discussed above. The embedded software isdesigned to use “flags” for different applications. The followingdescribes Leak-Tek™ software executed by a general purpose computersystem detachably coupled to the IGLS 9 in order to configure the IGLS9, receive data from the IGLS 9, and store data from the IGLS 9 forfuture analysis description of the software screens below and theabove-described flowchart of FIG. 3 demonstrate the process used by thesoftware.

[0145] The initial main screen the Leak-Tek™ software allows the user toenter test parameters (setup screen), configure the software and theIGLS 9 or calibrate the IGLS 9 (calibration and configuration screens),load and analyze previous test data files (SPC screen) or exit thesoftware program (main screen).

[0146] The setup screen allows a user to perform a variety of tasks andallows access to a run screen and a part data screen. The setup screenallows a user to perform the functions listed below:

[0147] choose a sensor for a test;

[0148] choose from a predefined list of units for temperature, pressure,time base, and flow units;

[0149] enter test parameters such as part number, part name ordescription, and test fill delay time;

[0150] enter parameters pertaining to gas parameters as used in a test;

[0151] add, delete or load part data from a database file;

[0152] set a pressure at which to perform the test

[0153] set high and low pressure limits or thresholds that trigger afault when reached or surpassed;

[0154] run a leak test via the run screen;

[0155] save setup screen parameters to a datafile;

[0156] download setup screen parameters to the IGLS 9 including gasconstants;

[0157] upload setup parameters from the IGLS 9;

[0158] exit setup screen to main screen; and

[0159] print current setup information.

[0160] The run screen can be accessed from the main screen to allow auser to choose a sensor for a test, save test data to a file forstatistical process control (SPC) analysis, automatically save test datainto a data file for SPC analysis upon each test conducted, or exit backto the main screen.

[0161] The setup screen allows the user to choose part setup data from adata file, add a new part number and description to the part data file,delete an obsolete part from the data file, or exit back to the mainscreen.

[0162] The configuration screen can be accessed from the main screen andallows a user to choose a sensor for a test, to enter PID parameters, tochoose the COMM port used by the computer to communicate with themicrocontroller 96, 596, to provide the coefficients needed by themicrocontroller 96, 596 to perform the appropriate flow calculations, toenable remote clamping, to enable automatic fill, to enable automaticpressuring or vacuuming, to enable total mass calculations, total volumecalculations, mass flow rate calculations, and volumetric flow ratecalculations, to set the buffer size for a particular set of test data,to save configuration data parameters to a data file, to downloadconfiguration parameters to a sensor in the test as well as a data file,to upload configuration parameters from a sensor, or to exit back to themain screen. The configuration screen also allows the user to access thecalibration screen. There are three calibration choices in theconfiguration screen: temperature, flow rate and static pressure. Eitherof these “buttons” can be chosen in the configuration screen and eachwill allow the user to access the calibration screen. The “button”chosen in the configuration screen will determine which sensor will becalibrated in the calibration screen.

[0163] The user in the configuration screen will also be allowed toselect the operating mode. In particular the user in may select anautomatic leak detection mode in which the microcontroller 96, 596controls valves of the test system, or a manual leak detection modewhich sets the test in a manual mode without PID control.

[0164] The calibration screen can be accessed as discussed earlier fromthe configuration screen. The calibration screen allows the user toenter a standard in the third column of the calibration parameters tableto determine a percent error during the calibration process, to examinethe offset and slope for the collected calibration date, to capture acount for data analysis, to download new calibration parameters into theIGLS 9, to remove a data point or to exit back to the configurationscreen.

[0165] The final screen that can be accessed from the main screen is theSPC screen which allows the user to view X-bar and R charts from ASCII(comma separated value) CSV files generated from the test screen, toload a CSV file for analysis, to examine an SPC analysis of a currentlyloaded CSV file, or to exit back to the main screen.

[0166] While the invention has been illustrated and described in detailin the drawings and foregoing description, such illustration anddescription is to be considered as exemplary and not restrictive incharacter, it being understood that only exemplary embodiments have beenshown and described and that all changes and modifications that comewithin the spirit of the invention are desired to be protected.

What is claimed is:
 1. A leak sensor comprising: a body comprising aconical bore between a first end and a second of the body, a firstreceiving port through the body to the conical bore, and a secondreceiving port through the body to the conical bore, a center shaftpositioned within the conical bore to define a flow gap such that afirst end of the center shaft is within the conical bore and a secondend of the center shaft is within the conical bore, a differentialpressure sensor coupled to the conical bore via the first receiving portand the second receiving port, the differential pressure sensor operableto generate a differential pressure signal representative of adifferential pressure developed between the first receiving port and thesecond receiving port, and a microcontroller coupled to the differentialpressure sensor to receive the differential pressure signal, themicrocontroller operable to determine whether the product leaked anunacceptable amount during the test period based upon the differentialpressure signal, wherein the first receiving port is located between thefirst end of the body and the first end of the center shaft and thesecond receiving port is located between the second end of the body andthe second end of the center shaft.
 2. A leak sensor comprising: a bodycomprising a conical bore between a first end and a second of the body,a first receiving port through the body to the conical bore, and asecond receiving port through the body to the conical bore, a centershaft positioned within the conical bore to define a flow gap, amanifold coupled to the body such that the manifold routes the firstreceiving port of the body to a first port of the manifold and thesecond receiving port of the body to a second port of the manifold, adifferential pressure sensor coupled to the first receiving port and thesecond receiving port via the first port and second port of themanifold, the differential pressure sensor operable to generate adifferential pressure signal representative of a differential pressuredeveloped between the first receiving port and the second receivingport, and a microcontroller coupled to the differential pressure sensorto receive the differential pressure signal, the microcontrolleroperable to determine whether the product leaked an unacceptable amountduring the test period based upon the differential pressure signal.
 3. Amolecular flow sensor, including: a body that defines a flow path;wherein the sensor measures mass flow through the flow path in themolecular flow regime.